Storage stable powder compositions of interleukin-4 receptor

ABSTRACT

The present invention provides storage stable dry powder compositions of IL-4R. The powder compositions demonstrate superior chemical and physical stability over their solution counterparts, particularly upon storage under varying conditions of temperature and humidity. Moreover, the powders, as prepared, possess good aerosol properties, which are maintained upon storage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/048,364, filed Feb. 1, 2005, which is a continuation of U.S. patentapplication Ser. No. 10/032,238, now U.S. Pat. No. 6,896,906, issued May24, 2005, which claims the benefit of priority of U.S. ProvisionalPatent Application Ser. No. 60/256,786, wherein the contents of each ofthe foregoing are incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention generally relates to spray dried, inhaleablepowder compositions of interleukin-4 receptor (IL-4R) and to methods formaking and pulmonarily administering such compositions. The powders ofthe invention are particularly stable with respect to monomer contentand aggregate level upon both preparation and storage, and additionallypossess superior aerosol properties, even in the absence of stabilizingcarriers or excipients. The powders of the invention, when administeredto the deep lung, are useful for treating allergic diseases, such asasthma, atopy, and atopic dermatitis.

BACKGROUND OF THE INVENTION

Interleukin 4 (IL-4, also known as B cell stimulating factor, or BSF-1)is a cytokine produced by T helper cells, mast cells, and basophils.IL-4 has been shown to possess a broad spectrum of biologicalactivities, including growth co-stimulation of T cells, mast cells,granulocytes, megakaryocytes, and erythrocytes. In addition, IL-4stimulates the proliferation of several IL-2 and IL-3 dependent celllines, induces the expression of class II major histocompatibilitycomplex molecules on resting B cells, influences the production of IgEand enhances the secretion of IgE and IgG₁ isotypes bylipopolysaccharide-stimulated B cells. IL-4 has been identified to playa critical role in the development of allergic diseases, and is mostcommonly associated with asthma and allergies; or diseases characterizedby difficulty breathing.

IL-4 binds to IL-4 receptor (IL-4R), an endogenous membrane-boundprotein on the surface of certain cells. Upon such binding, IL-4Rtransduces a biological signal to various immune effector cells, therebytriggering a cascade of events that lead to clinical symptoms (Renz H etal., 1991, J Immunol, 146(9):3049-55). Nucleotide and protein sequencedetermination for IL-4R has been carried out. Mature human IL-4R hasthree domain structures: an extracellular domain (about 207 aminoacids), a membrane passage region (about 24 amino acids), and anintracytoplasmic domain (about 569 amino acids) (European Patent No. EP585-681 (1994)). Soluble IL-4R (sIL-4R) has also been isolated, clonedand extensively investigated (European Patent No. EP 367-566(1997);Mosley et al., 1989, Cell, 59-335, 1989; U.S. Pat. No. 5,767,065 andGarrone P et al., 1991, EurJImmunol, 21(6):1365-9). IL-4 preferentiallybinds to sIL-4R in solution rather than to the endogenous cell-surfaceIL-4R, thereby preventing cellular activation and blocking thebiological response, e.g., the cascade of effects associated with IL-4and its binding to the endogenous receptor (Renz H et al., 1991, supra.and Renz, H, 1999, Inflamm Res., 48(8): 425-31).

IL4-R has been described as an immunosuppressant and ananti-inflammatory agent, and administration of IL-4R may be beneficialin the treatment of conditions such as allergy, rhinitis, atopicdermatitis, rheumatoid arthritis, graft rejection, chronicgraft-versus-host disease (GvH) and systemic lupus erthematosus (SLE)(See, e.g., U.S. Pat. No. 5,856,296; Renz H et al., 1992, J InvestDermatol, 99(4):403-8; Hackstein H et al., 1999, Tissue Antigens,54(5):471-7; Rivas D et al., 1995, J Autoimmun, 8(4):587-600; andSchorlemmer H U et al., 1995, Inflamm Res, 44 Suppl 2:S194-6).

Like many biopeptides, IL-4R tends toward instability. It tends todegrade and/or aggregate under extreme conditions (e.g., highly acidicor basic pH, high temperatures) and is susceptible to oxidizing agentsand endogenous proteases. The inherent chemical and physical instabilityof IL-4R makes pharmaceutical formulation particularly problematic. Tomaintain the stability and bioactivity of the protein, current IL-4Rformulations are primarily solution-based, and stored prior toadministration as lyophilizates (e.g., U.S. Pat. Nos. 5,856,296;5,767,065, and 6,063,371). A soluble, solution-based IL-4R peptidecomposition for administration by inhalation, Nuvance™, is currently inclinical trials for the treatment of asthma (Borish L C et al., 1999, AmJ Resp Crit Care Med, 160(6): 1816-23).

Solution-based formulations of IL-4R suffer from drawbacks other thanthose associated with solution phase instability. First, solution-basedformulations take up more room and require more care than solidformulations and, thus, are more costly. Moreover, in general, they mustbe refrigerated (typically maintained in an environment of 2 to 8° C.)which further restricts the storage and transport options. In addition,many solution-based formulations exhibit a protein concentration lossover time, which is presumably due to the formation of dimers and otherprotein aggregates in solution. Such formulations frequently must besupplemented with stabilizing additives such as buffers and/orantioxidants to minimize solution instability. Thus, it would bedesirable to provide a solid or powder-based composition of IL-4R,particularly one that could not only be stably prepared and stored, butadditionally administered in solid form, such as an inhaleable drypowder. Many preclinical and clinical studies with inhaled proteins,peptides, DNA and small molecules have demonstrated efficacy both withinthe lungs and systemically.

Powder formulations represent an alternative to solution formulations,and proteins, when desired in powder form, are most often prepared aslyophilizates (e.g., U.S. Pat. No. 5,856,296). Unfortunately,lyophilized powders are typically formed as cakes, which requireadditional grinding and milling, and optionally sieving processing stepsto provide flowing powders. In the past few years, spray drying has beenemployed as an alternative approach for preparing a number oftherapeutic protein-based powders, particularly for aerosolizedadministration (e.g., International Patent Publication Nos. WO 96/32149;WO 95/31479; WO 97/41833, assigned to Inhale Therapeutic Systems, Inc.).Unfortunately, certain proteins, and cytokines in particular, are proneto degradation during spray drying and loss of their secondary structure(Maa, Y. F., et al., J. Pharm. Sciences, 87 (2), 152-159 (1998)). For arepresentative cytokine, human growth hormone, Mumenthaler reported thatspray drying at 90° C. resulted in 4% formation of insoluble aggregatesand 21% formation of soluble aggregates—a loss of 25% intact protein(Pharmaceutical Res., 11, 12-20 (1994)). The instability of theillustrative cytokine, hGH, was further demonstrated by Maa, Y. F., etal., ibid, who reported 42% aggregate formation (soluble and insoluble)upon atomization of a solution of hGH.

Additionally, sIL-4R possesses a number of potential instability sitesleading to both solution and solid state-based instability.Specifically, sIL-4R contains 7 cysteines (Cys11, 21, 31, 51, 61, 63 and184), ensuring at least one free sulfhydryl which may be available forintermolecular disulfide linkages. Such intermolecular disulfidelinkages lead to the ready formation of dimers, trimers and otherself-aggregates. Thus, this molecule is particularly prone toinstability. In addition to sites susceptible to aggregation, the IL-4Rpeptide also has sites susceptible to degradation. For example, siteslikely vulnerable to oxidative attack include four methionine residues(Met3, 16, 25, and 67). Additionally, an acid labile Asp-Pro linkagedisruptable at low pH is found at amino acid residues 145-146. Twolikely deamidation sites include Asn-Gly (26-27), and Asn-Gly (56-57),although the molecule possesses numerous other potential deamidationresidues (Asn and Gln).

Thus, the challenge facing the inventors was not only to provide animproved dry powder formulation of IL-4R for overcoming some of thedisadvantages associated with solution-based formulations of IL-4R asdescribed above, but also to balance the factors affecting theinstability and aerosol properties of IL-4R to arrive at a stable drypowder formulation suitable for pulmonary administration. That is tosay, prior to the present invention, the development of a chemically andphysically stable, bioactive dry powder of IL-4R that also possesses thephysical properties necessary for aerosolization (e.g., highdispersibilities which remain stable over time, appropriate aerodynamicsize) was unknown.

SUMMARY OF THE INVENTION

The present invention is based upon the unexpected discovery ofchemically and physically stable spray dried powder compositions ofIL-4R, even though such molecules (i.e., cytokines) are known to beparticularly unstable when exposed to the shear stress, liquid-wallinteractions, high temperature conditions and the like of spray drying.Surprisingly, the spray-dried powder of the invention exhibits both amonomer content and aggregate level that is essentially unchangedrelative to that of its pre-spray dried solution. Moreover, theinvention provides IL-4R dry powder compositions that are storage stablewith respect to both monomer content and aggregate level, even underextreme conditions of humidity. That is to say, the spray dried powdersdescribed herein exhibit both superior chemical and physical stability,as well as having good dispersibilties, (i.e., aerosol properties)making them suitable for administration to the lung.

In one aspect, the invention provides a spray dried IL-4R powdercomposition that is capable of being stored for extended periods oftime, 14 days or more, in extreme humitidy and temperature conditionswithout experiencing substantial alterations in aerosol performance,chemical and/or physical character, bioactivity, and the like. Moreparticularly, the IL-4R content of the powder compositions of thepresent invention is essentially unchanged as compared to the pre-spraydried suspensions or solutions, i.e., experiencing minimal aggregateformation and/or protein monomer loss over time.

The IL-4R powder composition, demonstrating insignificant degradationupon preparation and storage, may be prepared in the absence ofstabilizing additives or excipients, or may further include apharmaceutically acceptable excipient. Preferred excipients include zincsalts, citrate, leucine, and combinations thereof.

The IL-4R powder composition preferably has a monomer content that issubstantially unchanged as compared to that of the pre-dried solution orsuspension. The change in monomer content is presented herein as apercent decrease (as compared to pre-dried solution or suspension). Thedecrease in monomer content is preferably less than about 10%, morepreferably less than 7%, most preferably less than 5%.

The IL-4R powder composition preferably exhibits minimal aggregateformation as compared to that of the pre-dried solution or suspension.The level of aggregate formation is presented herein as a percentincrease (as compared to pre-dried solution or suspension). The increasein aggregate content is preferably less than 10%, more preferably lessthan 7%, most preferably less than 5%.

Additionally, the IL-4R powder compositions of the invention compriseparticles effective to penetrate into the alveoli of the lungs, that is,having in a particular embodiment, a mass median diameter (MMD) of lessthan about 10 μm, preferably less than about 7.5 μm, and most preferablyless than 5 μm in diameter. In a particularly preferred embodiment, thepowder is composed of particles having an MMD from about 1.0 to 3.5 μm.

Further embodiments of the IL-4R powder compositions in accordance withthe invention include spray dried IL-4R particles having a mass medianaerodynamic diameter (MMAD) of less than about 10 microns, preferablyless than about 5.0 microns, and more preferably less than about 3.5microns. In an especially preferred embodiment, the MMAD ranges from 1.5to 3.5 microns.

Also encompassed by the invention is an aerosolized IL-4R powderformulation, and an IL-4R powder in a unit dosage form.

In another aspect, the invention is directed to a method foradministering an IL-4R powder composition as described herein to thelungs of a patient in need thereof. In the method, a composition asdescribed above is administered by inhalation in aerosolized form.

The invention also encompasses, in yet another aspect, a method forpreparing a dispersible, dry IL-4R powder composition having thefeatures described above.

In one embodiment, the respirable IL-4R powder composition is preparedby combining the active IL-4R agent(s) in a suitable solvent to form amixture or solution and spray-drying the mixture or solution to obtaindiscrete, substantially amorphous particles, preferably in the form of adry powder. The IL-4R remains essentially intact upon spray drying,resulting in powder particles in which the extent of protein degradation(as characterized by decrease in monomer content and aggregateformation) is insignificant.

An optional pharmaceutical excipient may be further added to the solventto form a homogeneous solution or heterogeneous mixture, such thatspray-drying of the solution or mixture produces particles comprising,in combination with IL-4R, excipient, buffer, and any other componentswhich are present in the solution or mixture. Alternatively, thepharmaceutical excipient may be separately dissolved and spray dried toyield separate yet co-administrable powder particles.

These and other objects and features of the invention will become morefully apparent when the following detailed description is read inconjunction with the accompanying figures and examples.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1: This figure represents a graph of the effect of temperature onmonomer content of spray dried powders, Formulations 1(A)-1(D) ofExample 1 (2 week stability data).

FIG. 2: This figure represents a graph of the effect of relativehumidity on monomer content of spray dried powder, Formulations1(A)-1(D) of Example 1 (2 week temperature stability data).

FIG. 3: This figure represents a graph of the effect of temperature onmonomer content of spray dried powders, formulations 1(A)-1(D) ofExample 1 (2 week temperature stability data).

DETAILED DESCRIPTION OF THE INVENTION

A. Definitions

The following terms as used herein have the meanings indicated.

In the context of the present invention, “IL-4R” and “sIL-4R” refer tothe extracellular domain of the cell-bound protein that acts as receptorfor the cytokine, interleukin-4. As discussed below, IL-4R as usedherein is not limited to a single peptide sequence, but is meant toencompass any known protein having IL-4R activity, including naturallyand synthetically derived IL-4R as well as agonists and analogs thereof,to the extent that they retain the therapeutic activity associated withnative peptide.

As used herein, the term “agonist” refers to compounds which mimic theeffect of the native compound. An agonist may be a peptide or anon-peptide compound.

As used herein, the term “analog” refers to those compounds in which oneor more amino acids have been substituted, deleted (i.e., fragments),added, or otherwise modified from the native (wild-type) human sequence,and which exhibits at least about 10, 20, 30, or 40%, and preferably atleast 50%, 60%, or 70%, and most preferably at least 80%, 90%, 95%, 100%or greater than 100% bioactivity of that of the native (non-synthetic),endogenous peptide. The receptor specificity is optionally substantiallysimilar to the native (wild-type), endogenous peptide. Typically, thereceptor affinity will be at least 30%, 40%, or 50% that of the native(wild-type), endogenous peptide; more preferably at least 60%, 70%, 80%,90%, 95%, 100% or greater than 100%.

Compositions of the present invention are considered to be “respirable”if they are suitable for inhalation therapy (i.e., capable of beinginspired by the mouth or nose and drawn into the lungs) and/or pulmonarydelivery (i.e., local delivery to the tissues of the deep lung andabsorption through the epithelial cells therein into blood circulation).Compositions of the present invention are preferably suitable for rapidsystemic absorption through the lungs, i.e., peaking in blood in lessthan 60 minutes.

As used herein, “deep lung” refers to the alveolar regions of the lung(as opposed to the bronchial regions). A composition suitable for“inhalation therapy”, is one which, when aerosolized, may be (i) readilydispersed in an oral inhalation or intranasal delivery device, and (ii)inspired through either the mouth or nose by a mammalian subject so thatat least a portion of the particles are absorbed through the mucousmembranes of the nasal passages or the lung. A composition suitable for“pulmonary administration” comprises particles at least a portion ofwhich, when delivered via inhalation in aerosolized form, reach thetissues of the lung, including the deep lung.

“Orally respirable” compositions are those respirable compositions thatare particularly adapted for oral inhalation. Likewise, “nasallyrespirable” compositions are those respirable compositions that areparticularly adapted for nasal inhalation, i.e., intranasal deliveryinto the upper respiratory tract.

“Dry powder” refers to respirable composition that contains finelydispersed solid particles that are relatively free flowing and capableof (i) being readily dispersed in an inhalation device and (iii) inhaledby a subject so that a portion of the particles reach the lungs topermit penetration to the alveoli. The dry powder may be crystalline, anamorphous glass or a mixture of both forms. A dry powder typicallycontains less than about 10% moisture, preferably less than about 5%moisture, and more preferably contains less than about 3% moisture.

“Emitted Dose” or “ED” provides an indication of the delivery of a drugformulation from a suitable inhaler device after a firing or dispersionevent. More specifically, for dry powder formulations, the ED is ameasure of the percentage of powder which is drawn out of a unit dosepackage and which exits the mouthpiece of an inhaler device. The ED isdefined as the ratio of the dose delivered by an inhaler device to thenominal dose (i.e., the mass of powder per unit dose placed into asuitable inhaler device prior to firing). The ED is anexperimentally-determined parameter, and is typically determined usingan in-vitro device set up which mimics patient dosing. To determine anED value, a nominal dose of dry powder, typically in unit dose form, isplaced into a suitable dry powder inhaler (such as the described in U.S.Pat. No. 5,785,049, assigned to Inhale Therapeutic Systems) which isthen actuated, dispersing the powder. The resulting aerosol cloud isthen drawn by vacuum from the device, where it is captured on a taredfilter attached to the device mouthpiece. The amount of powder thatreaches the filter constitutes the emitted dose. For example, for a 5mg, dry powder-containing dosage form placed into an inhalation device,if dispersion of the powder results in the recovery of 4 mg of powder ona tared filter as described above, then the emitted dose for the drypowder composition is: 4 mg (delivered dose)/5 mg (nominaldose)×100=80%. For non-homogenous powders, ED values provide anindication of the delivery of drug from an inhaler device after firingrather than of dry powder, and are based on amount of drug rather thanon total powder weight. Similarly for MDI and nebulizer dosage forms,the ED corresponds to the percentage of drug which is drawn from a unitdosage form and which exits the mouthpiece of an inhaler device.

A “dispersible” powder is one having an ED value of at least about 30%preferably at least about 40%, more preferably at least about 50%, andeven more preferably at least about 55%.

“Mass median diameter” or “MMD” is a measure of mean particle size,since the powders of the invention are generally polydisperse (i.e.,consist of a range of particle sizes). MMD values as reported herein aredetermined by centrifugal sedimentation, although any number of commonlyemployed techniques can be used for measuring mean particle size (e.g.,electron microscopy, light scattering, laser diffraction.

“Mass median aerodynamic diameter” or “MMAD” is a measure of theaerodynamic size of a dispersed particle. The aerodynamic diameter isused to describe an aerosolized powder in terms of its settlingbehavior, and is the diameter of a unit density sphere having the samesettling velocity, in air, as the particle. The aerodynamic diameterencompasses particle shape, density and physical size of a particle. Asused herein, MMAD refers to the midpoint or median of the aerodynamicparticle size distribution of an aerosolized powder determined bycascade impaction, unless otherwise indicated.

“Fine Particle Fraction” (FPF_(<3.3 μm)) is defined as the dose ofpowder which is under 3.3 microns as determined by cascade impaction.This parameter corresponds to the total mass under stage 3 of anAndersen impactor when operated at a flow rate of 1 cfm (28.3 L/min).

“Pharmaceutically acceptable excipient” and “pharmaceutically acceptablecarrier” are synonymous and refer to excipients that may be included inthe formulations of the invention and taken into the lungs inassociation with the particles with no significant adverse toxicologicaleffects to the subject, and particularly to the lungs of the subject.

“Pharmacologically effective amount” or “physiologically effectiveamount” is the amount of IL-4R present in an inventive composition asdescribed herein that is needed to provide a desired level of IL-4R inthe bloodstream of tissue of a subject to be treated and thereby providean anticipated physiological response when such composition isadministered by inhalation for deposition in and absorption from thelung. The precise amount will depend upon numerous factors, e.g., theparticular IL-4R used (e.g., natural or synthetic, full-length orfragment or analog), the delivery device employed, the physicalcharacteristics of the powder, the intended patient use (e.g., thenumber of doses administered per day), and the patient considerations(e.g., age, size weight, health, etc.), and can be determined by oneskilled in the art, based upon the information provided herein.

A “surface active agent” is an excipient having surface activity(measured, e.g., by surface tensiometry), as characterized by itsability to reduce the surface tension of the liquid in which it isdissolved and cause drugs associated with it to spread rapidly overmucosal surfaces. Surface tension, which is associated with theinterface between a liquid and another phase, is that property of aliquid by virtue of which the surface molecules exhibit an inwardattraction. The term also includes detergents, emulsifiers, penetrants,and wetting agents.

By “water soluble peptide” is meant a peptide having a solubility inwater of at least 0.5 mg/ml, and more preferably of at least 1 mg/ml.

“Amino Acid” refers to any compound containing both an amino group and acarboxylic acid group, and includes pharmaceutically acceptable saltsthereof. Although the amino group most commonly occurs at the positionadjacent to the carboxy function, the amino group may be positioned atany location within the molecule. The amino acid may also containadditional functional groups, such as amino, thio, carboxyl,carboxamide, imidazole, etc. The amino acids may be synthetic ornaturally occurring and may be used in either their racemic or opticallyactive (D-, or L-) forms, for example, as a single optically activeenantiomer or as any combination or ratio of enantiomers.

A “dispersing agent” refers to a component of the respirable 11-4Rpowder compositions described herein that is effective, when present infrom 0.01 to 99 percent by weight of the composition, preferably from0.01 to 70 percent by weight, to increase the dispersiblity of therespirable IL-4R powder compositions (determined by emitted dosedetermination) by at least 10% when compared to the dispersibility ofthe respirable IL-4R composition absent the dispersing agent.

“In-lung pulmonary bioavailability” or “relative bioavailability” is thepercentage of the IL-4R administered dose which has been deposited inthe lungs, and which is absorbed and becomes available in the systemiccirculation of a mammal relative to the percent that is absorbed intothe blood from an intramuscular or subcutaneous injection site.Representative model systems for determining in-lung bioavailabilitiesinclude rat, rabbit, and monkey. In-lung pulmonary bioavailabilities maybe based upon direct intratracheal administration or by inhalation of arespirable IL-4R powder composition as described herein.

“Bulk density” refers to the density of a powder prior to compaction(i.e., the density of an uncompressed powder), and is typically measuredby a well-known USP method.

“Essentially unchanged” as used in reference to monomer content oraggregate level of an IL-4R powder composition of the invention refersto a composition which exhibits a change of no more than about 2% ineither monomer content or aggregate level when compared to that of thecorresponding pre-spray-dried solution or suspension.

A “minimal increase” when used in reference to IL-4R aggregate level ina spray dried IL-4R powder refers to an increase in the level ofaggregates of no more than about 10% in comparison to the level ofaggregates in the corresponding pre-spray dried solution or suspension.

A “minimal change” when used in reference to IL-4R monomer content in aspray dried IL-4R powder refers to a change (i.e., decrease) in monomercontent of no more than about 10% in comparison to the level of IL-4Rmonomer in the corresponding pre-spray dried solution or suspension.

“Humid condition” refers to an environment having a relative humiditygreater than 30% relative humidity (RH). A particularly humidenvironment is one having a relative humidity greater than about 60% RH,with high humidities ranging from about 70% to 75% RH or greater.

B. Components of the Respirable IL-4R Powder Composition

The present invention provides highly dispersible respirable powdercompositions containing IL-4R for pulmonary delivery thereof. The powdercompositions described herein overcome many of the problems oftenencountered heretofore in administering peptide agents by systemicroutes, particularly the problems associated with solution-basedformulations of IL-4R. Examples of such problems include prolongedresponse time (e.g., time between administration and onset ofphysiological response), low systemic absorption and relatively lowconcentrations in tissues and secretions, the inability to maintainacceptable serum levels, and the instability of peptides, and cytokinesin particular, in solution.

The compositions of the present invention are particularly effective forthe treatment of allergic diseases and conditions, such as asthma andatopic dermatitis. Moreover, the spray dried IL-4R powder containingcompositions described herein are surprisingly stable (i.e., exhibitminimal chemical and physical degradation upon preparation and storage,even under extreme conditions of temperature and humidity). That is tosay, the powders provided herein are surprisingly robust, even in theabsence of stabilizing or dispersibility enhancing excipients. The IL-4Rpowders of the invention (i) are readily dispersed by aerosol deliverydevices (i.e., demonstrate good aerosol performance), (ii) exhibitsurprisingly good physical and chemical stability during powdermanufacture and processing, and upon storage, and (iii) are reproduciblyprepared (Examples 1-5).

The respirable IL-4R powder compositions according to the presentinvention contain IL-4R, and, optionally but not necessarily, apharmaceutically acceptable excipient. The components of the respirableIL-4R powder compositions of the invention will now be described.

IL-4R for use in the invention is generally characterized as follows.Endogenous mature interleukin-4 receptor is expressed as a 140 kDAmembrane glycoprotein that binds IL-4 with high affinity (Idzerda R L etal., 1990 J. Exp. Med., 171 (3), 861-873; Jacobs, C A et al. 1991,Blood, 77(11):2396-2403, both of which are incorporated by referenceherein). The extracellular domain of human IL-4R, cloned and produced inCHO cells in serum containing media, is a highly glycosylated (N-linked)and sialylated protein having a nonglycosylated molecular weight of 23.9kDa and containing 209 amino acid residues. The extracellular domainIL-4R is located between residues 24 and 234 of the mature interleukin-4receptor. Mass spectrometry data shows the protein molecular weight tobe about 37 kDa, suggesting at least 35% glycosylation. By SDS-PAGEanalysis, the protein elutes as a 54 kDa band. The pI of IL-4R is 3.36to 5.18 as determined by isoelectric focusing. The unfolding transitiontemperature as determined by DSC is 57.8° C. and the unfolding processis highly reversible.

IL-4R for use in the compositions described herein may be purchased froma commercial source, or may be recombinantly produced, for example,using a process described in U.S. Pat. No. 5,767,065 and by Armitage etal. in Adv Exp Med Biol 1991; 292:121-30, both of which are incorporatedby reference herein in their entirety. The IL-4R may be neutral (i.e.,uncharged) or may be in the form of a pharmaceutically acceptable salt,for example, an acid addition salt such as acetate, maleate, tartrate,methanesulfonate, benzenesulfonate, toluenesulfonate, etc., or aninorganic acid salt such as hydrochloride, hydrobromide, sulfate,phosphate, etc. Cationic salts may also be employed, such as salts ofsodium, potassium, calcium, magnesium, or ammonium salts.

The amount of IL-4R contained within the respirable powder compositionswill be that amount necessary to pulmonarily deliver a therapeuticallyeffective amount (i.e., amount required to exert the therapeutic effect)of IL-4R per unit dose over the course of a daily dosing regimen. Inpractice, this will vary depending upon the particular IL-4R (e.g.,natural vs. synthetic, full-length vs. fragment and its correspondingbioactivity), the patient population, and dosing requirements. Due tothe highly dispersible nature of the respirable powders of theinvention, losses to the inhalation device are minimized, meaning thatmore of the powder dose is actually delivered to the patient. This, inturn, correlates to a lower required dosage to achieve the desiredtherapeutic goal.

In general, the total amount of IL-4R contained in the respirable powdercompositions will range from 1 to 100% of the total weight of therespirable powder composition, preferably from 5 to 98%, more preferablyfrom 10 to 95%, even more preferably from about 45% to 95% by weight toabout 50% to about 90%. A preferred dry powder composition will containfrom about 40% to 80% IL-4R (% by weight of composition), and even morepreferably will contain from about 0.2% to 99% IL-4R by weight.

The effective amount of IL-4R required will vary from one patient to thenext and from one therapeutic regimen to the next. The amount andfrequency of administration will depend, of course, on such factors asthe nature and severity of the indication being treated, the desiredresponse, the patient population, condition of the patient, and soforth.

The generally accepted dosage appropriate for inducing a biologicaleffect for parenterally administered sIL-4R ranges from about 1ng/kg/day to about 10 mg/kg/day, more preferably from about 5 ug/kg/dayto about 2 mg/kg/day. Such parenteral formulations of IL-4R arediscussed in U.S. Pat. Nos. 5,856,296 and 6,063,371, discussed above.However, since pulmonary delivery is frequently more efficient thanparenteral delivery, dosages required may vary, and in fact, may beslightly less than those utilized in parenteral formulations. Dosing ofIL-4R, particularly for the treatment of allergic diseases such asasthma, is typically weekly. Weekly dosage of an IL-4R powder byinhalation can range from about 0.1 to 10 mg, more preferably between0.5-5 mg, even more preferably between 1-2 mg. Precise dosages willdepend upon various factors such as the concentration of IL-4R in thespray dried powder. Desired dosages are typically achieved in 1 to 10breaths or 2 to 6 breaths, more preferably 1-4 breaths, depending uponthe precise unit dosage form employed.

The efficiency of systemic Il-4R delivery via the method describedherein, i.e., the percentage of administered dose that reaches thebloodstream (e.g., in lung pulmonary bioavailability) from a solidinhaled dosage form will typically be at least about 1%, more preferablyat least about 2%, typically at least about 3-5%. In a more preferredembodiment, the efficiency of systemic delivery into the bloodstreamfrom the lung is at least about 15% to 30%.

C. Excipients and Additives

The respirable powder compositions of the present invention may beformulated “neat” i.e. without pharmaceutical excipients or additives.This finding was particularly surprising in view of the tendency ofcytokines such as IL-4R towards both degradation and aggregation. In onespecific embodiment of the invention, the respirable composition is a“neat” dry powder formulation. In another embodiment, the dry powderformulation is absent particular excipients and additives, such aspenetration enhancers.

Alternatively, the compositions of the invention may contain IL-4Rcombined with one ore more pharmaceutically acceptable excipients oradditives that are suitable for respiratory and pulmonaryadministration. Such excipients, if present, are generally present inthe powder composition in amounts ranging from about 0.01% to about 99%percent by weight, preferably from about 0.1% to about 95%, morepreferably from about 0.5% to about 80%, even more preferably from about1% to about 50-60%. Examples of excipient-containing respirable Il-4Rcompositions are described in Example 1. Interestingly, in the exemplarycompositions described in the Examples, the presence or absence of oneor more excipients did not substantially impact the chemical or physicalstability of the spray dried powders of the invention, either duringpreparation or storage.

However, preferred excipients will, in part, serve to improve one ormore of the following: the aerosol properties of the composition, itschemical stability, its physical stability, and/or storage stability.Preferred excipients may also function to provide more efficient andreproducible delivery of IL-4R by dry powder inhaler, and additionallyimprove the handling characteristics of the IL-4R powder composition(e.g., flowability and consistency) to facilitate manufacturing andpowder filling.

In particular, the excipient materials can often function to improve thephysical and chemical stability of the respirable IL-4R powdercomposition or active agents contained therein. For example, theexcipient may minimize the residual moisture content and hinder moistureuptake and/or enhance particle size, degree of aggregation, surfaceproperties (i.e., rugosity), ease of inhalation, and targeting of theresultant particles to the lung. The excipient(s) may also simply servesimply as bulking agents for reducing the active agent concentration inthe dry powder composition.

Pharmaceutical excipients and additives useful in the presentcomposition include, but are not limited to, proteins (i.e., largemolecules composed of one or more chains of amino acids in a specificorder), oligopeptides (i.e., short chains of amino acids connected bypeptide bonds), peptides (i.e., a class of molecules that hydrolyze intoamino acids), amino acids, lipids (i.e., fatty, waxy or oily compoundstypically insoluble in water but soluble in organic solvents, containingcarbon, hydrogen and, to a lesser extent, oxygen), polymers (i.e., largemolecules formed by the combination of many similar smaller molecules),and carbohydrates (e.g., sugars, including monosaccharides, di-, tri-,tetra-, and oligosaccharides; derivatized sugars such as alditols,aldonic acids, esterfied sugars and the like; and plysaccharides orsugar polymers), which may be present singly or in combination. Suitableexcipients include those provided in International Publication No. WO96/32096 assigned to Inhale Therapeutic Systems, Inc., the entirecontents of which are incorporated by reference herein.

Preferred excipients include sugar alcohols, lipids, DPPC, DSPC,calcium/magnesium, and hydrophobic excipients, such as hydrophobic aminoacids and hydrophobic sugars. Particularly preferred excipients includezinc salts, leucine, citrate, and sugars such as raffinose. Forparticulate formulations, preferred excipients are those having glasstransition temperatures (Tg), above about 35° C., preferably above about45° C., more preferably above about 55° C.

Exemplary polypeptide and protein excipients include serum albumin suchas human serum albumin (HSA), recombinant human albumin (rHA), gelatin,casein, hemoglobin, and the like. Particularly preferred aredispersibility enhancing polypeptides, e.g., HSA, as described inInternational Publication No. WO 96/32096, assigned to InhaleTherapeutic Systems, Inc., the contents of which are incorporated byreference herein.

Representative amino acid/polypeptide components, which may alsofunction in a buffering capacity, include alanine, glycine, arginine,betaine, histidine, glutamic acid, aspartic acid, cysteine, lysine,leucine, isoleucine, valine, methionine, phenylalanine, aspartame,tyrosine, tryptophan, and the like. Preferred are amino acids andpeptides that function as dispersing agents. Amino acids falling intothis categoray include hydrophobic amino acids such as leucine (leu),valine (val), isoleucine (isoleu), tryptophan (try) alinine (ala),methionine (met), phenylalanine (phe), tyrosine (tyr), histidine (his),and proline (pro). One particularly preferred amino acid is the aminoacid leucine. Leucine, when use in the formulations described hereinincludes D-leucine, L-leucine, and racemic leucine. Dispersibilityenhancing peptides for use in the invention include dimers, trimers,tetramers, and pentamers composed of hydrophobic amino acid componentssuch as those described above. Examples include di-leucine, di-valine,di-isoleucine, di-tryptophan, di-alanine, and the like, tripleucine,tripvaline, tripisoleucine, triptryptophan etc.; mixed di- andtri-peptides, such as leu-val, isoleu-leu, try-ala, leu-try, etc., andleu-val-leu, val-isoleu-try, ala-leu-val, and the like andhomo-tetramers or pentamers such as tetra-alanine and penta-alanine.Particularly preferred oligopeptide excipients are dimers and trimerscomposed of two or more leucine residues, as described in InhaleTherapeutic Systems Inc. International Patent Application PCT/US00/09785entitled, “Dry Powder Compositions Having Improved Dispersibity. Ofthese, dileucine and trileucine are particularly preferred.

Another preferred feature of an excipient for use in the invention issurface activity. Surface active excipients, which may also function asdispering agents, such as hydrophobic amino acids (e.g., leu, valisoleu, phe, etc.), di- and tri-peptides, polyamino acids (e.g.,polyglutamic acid) and proteins (e.g., HSA, rHA, hemoglobin gelatin) areparticularly preferred, since due to their surface active nature, theseexcipients tend to concentrate on the surface of the particles of therespirable IL-4R composition, making the resultant particles highlydispersible in nature. Other exemplary surface active agents that may beincluded in the respirable IL-4R compositions described herein includebut are not limited to polysorbates, lecithin, oleic acid, benzalkoniumchloride, and sorbitan esters.

Carbohydrate excipients suitable for use in the invention include, forexample, monosaccharides such as fructose, maltose, galactose, glucose,d-mannose, sorbose, and the like; disaccharides, such as raffinose,melezitose, maltodestrins, dextrans, straches and the like; andalditols, such asmannitol, xylitol, maltitol, lactitol, xylitol sorbital(glucito), myoinasitol and the like.

The respirable IL-4R compositions may also include a buffer or a pHadjusting agent; typically, the buffer is a salt prepared from anorganic acid or base. Representative buffers include organic acid saltssuch as salts of citric acid, ascorbic acid, gluconic acid, carbonicacid, taratric acid, succinic acid, acetic acid, or phthalic acid, Tris,tromethamine hydrochloride, or phosphate buffer.

Additionally, the respirable IL-4R composition of the invention mayinclude polymeric excipients/additives such as polyvinylpyrrolidones,derivatized celluloses such as hydroxypropylmethylcellulose, Ficcols (apolymeric sugar), hydroxyethylsartch, dextrates (e.g., cyclodextrins,such as 2-hydroxypropyl-β-cyclodextrin andsulfobutylether-β-cyclodextrin), polyethylene glycols, pectin flavoringagents, salts (e.g., sodium chloride), antimicrobial agents, sweeteners,antioxidants, antistatic agents, surfactants (e.g., polysorbates such as“TWEEN 20” and “TWEEN 80”), lecithin, oleic acid, benzalkonium chloride,sorbitan esters, lipids (e.g., phospholipids, fatty acids), steroids(e.g. cholesterol) and chelating agents (e.g., EDTA). For compositionscontaining a polymeric component, the polymer is typically present to alimited extent in the composition, i.e., at levels less than about 10%by weight. Preferred compositions of the invention are those in whichthe IL-4R is preferably non-liposomally or polymer encapsulated, ornon-coated (i.e., absent a discrete coating layer). Preferred IL-4Rcompositions such as those exemplified herein are immediate-actingformulations, i.e., designed for immediate rather than for sustainedrelease applications.

Other pharmaceutical excipients and/or additives suitable for use in therespirable IL-4R compositions according to the invention are listed in“Remington: the Science & Practice of Pharmacy”, 19^(th) ed., Williams &Williams, (1995, in the “Physician's Desk Reference”, 52^(nd) ed.,Medical Economics, Montvale, N.J. (1998), and in “The Handbook ofPharmaceutical Excipients”, 3^(rd) Edition, A. H. Kibbe, ed., AmericanPharmaceutical Association, Pharmaceutical Press, 2000, the disclosuresof which are herein incorporated by reference.

In accordance with the invention, the respirable IL-4R powdercomposition may be a dry powder, the dry powder being crystalline, anamorphous glass, or a mixture of both forms. For formulations containinga surface active agent, the surface active material (in eithercrystalline or amorphous form), will typical be present on the surfaceof the particles in a higher concentration than in the bulk powder.

D. Preparing the Respirable Il-4R Compositions

Respirable Il-4R powder compositions, such as dry powder formulationsare preferably prepared by spray-drying. Spray-drying of theformulations is carried out, for example, as described generally in the“Spray-drying Handbook”, 5^(th) ed., K. masters, John Wiley & Sons,Inc., NY, NY (1991), in Platz, R., et al., International PatentPublication Nos. WO 97/41833 (1997) and WO 96/32149 (1996), the contentsof which are incorporated herein by reference.

To prepare an IL-4R solution for spray-drying, IL-4R (and any otherexipients) is generally dissolved in water, optionally containing aphysiologically acceptable buffer. The pH range of solution is generallybetween about 3 and 10, which nearer neutral pHs being preferred, sincesuch pHs may aid in maintaining the physiological compatibility of thepowder after dissolution of powder within the lung. The aqueousformulation may optionally contain additional water-miscible solvents,such as acetone, alcohols and the like. Representative alcohols arelower alcohols such as methanol, ethanol, propanol, isopropanol, and thelike. The solutions will generally contain IL-4R dissolved at aconcentration from 0.01% (weight/volume) to about 20% (weight/volume),preferably from 0.1% to 10% (weight/volume), more preferably 1% to 3%(weight/volume). Alternatively, components of the IL-4R formulation maybe spray-dried using an organic solvent or co-solvent system, employingone or more solvents such as acetone, alcohols (e.g., methanol andethanol), ethers, aldehydes, hydrocarbons, ketones and polar aproticsolvents.

The IL-4R containing solutions are then spray dried in a conventionalspray drier, such as those available from commercial suppliers such asNiro A/S (Denmark), Buchi (Switzerland) and the like, resulting in adispersible, respirable IL-4R composition, preferably in the form of arespirable dry powder. Optimal conditions for spray-drying the activeagent solutions will vary depending upon the formulation components, andare generally determined experimentally. The gas used to spray-dry thematerial is typically air, although inert gases such as nitrogen orargon are also suitable. Moreover, the temperature of both the inlet andoutlet of the gas used to dry the sprayed material is such that it doesnot cause decomposition of the IL-4R in the sprayed material. Suchtemperatures are typically determined experimentally, althoughgenerally, the inlet temperature will range from about 50° C. to about200° C. while the outlet temperature will range from about 30° C. toabout 150° C.

The preparation of respirable, dry IL-4R powder compositions under avariety of spray-drying process parameters are described in Examples 1and 2. Surprisingly, the shear forces produced by atomization of thesolution during spray-drying do not result in hydrolysis or aggregationof IL-4R. As described herein, highly dispersible dry powders havinggood physical and chemical stability and good aerodynamic properties canbe prepared reproducibly and under a variety of process conditions.

Alternatively, although less preferably, the respirable IL-4R powdercompositions may be prepared by lyophilization, vacuum drying, sprayfreeze drying, super critical fluid processing, air drying, or otherforms of evaporative drying.

In some instances, it may be desirable to provide the respirable IL-4Rdry powder formulation in a form that possesses improvedhandling/processing characteristics, e.g., reduced static, betterflowability, low caking and the like, by preparing compositions composedof fine particle aggregates, that is, aggregates or agglomerates of theabove-described respirable IL-4R. Dry powder particles, where theaggregates are readily broken back down to the fine powder componentsfor pulmonary delivery, as described, e.g., in Johnson, K., et al., U.S.Pat. No. 5,654,007, 1997, incorporated herein by reference.Alternatively, the respirable IL-4R powders may be prepared byagglomerating the powder components, sieving the materials to obtain theagglomerates, spheronizing to provide a more spherical agglomerate, andsizing to obtain a uniformly-sized product, as described, e.g., inAhlneck, C., et al. International PCT Publication No. WO 95/09616(1995), incorporated herein by reference.

The respirable IL-4R dry powders are preferably maintained under dry(i.e., relatively low humidity) conditions during manufacture,processing, and storage. Irrespective of the drying process employed,the process will preferably result in respirable highly dispersiblecompositions composed of substantially amorphous IL-4R particles.

E. Characteristics of the Respirable IL-4R Powder Compositions

Certain physical characteristics of the spray dried IL-4R powdercompositions are preferred to maximize the efficiency of aerosolizeddelivery of such compositions to the lung.

The respirable IL-4R powder compositions are composed of particleseffective to penetrate into the lungs. Passage of the particles into thelung physiology is an important aspect of the present invention. To thisend, the particles of the invention have a mass median diameter (MMD) ofless than about 10 μm, preferably less than 7.5 μm, and more preferablyless than 5 μm, and usually are in the range of 0.1 μm to 5 μm indiameter. Preferred compositions are composed of particles having andMMD from about 0.5 to 3.5 μm. Examples of respirable IL-4R powdercompositions of varying concentrations of active agent(s) and/orexcipient are described in Example 1. The respirable IL-4R powdercompositions may also contain non-respirable carrier particles such aslactose, where the non-respirable particles are typically greater thanabout 40 microns in size. In a preferred embodiment, the dry powder isnon-liposomal or non-lipid containing.

The respirable IL-4R powder compositions of the invention are furthercharacterized by an aerosol particle size distribution less than about10 μm mass median aerodynamic diameter (MMAD), preferably less than 5.0μm, and more preferably less than 3.5 μm. The mass median aerodynamicdiameters of the powders will characteristically range from about 0.5-10μm, preferably from about 0.5-5.0 μm MMAD, more preferably from about1.0-4.0 μm MMAD, and even more preferably from about 1.5 to 3.5 μm.

The respirable IL-4R powder compositions, particularly the respirabledry powder compositions, generally have a moisture content below about10% by weight, usually below about 5% by weight, and preferably belowabout 3% by weight. Such low moisture-containing solids tend to exhibita greater stability upon packaging and storage.

The dry powders preferably have a bulk density ranging from about 0.1-10g/cc, preferably from about 0.25-4 g/cc, more preferably from about0.5-2 g/cc, and most preferably from about 0.7-1.4 g/cc.

The emitted dose (ED) of these powders is greater than 30% and usuallygreater than 40%. More preferably, the ED of the powders of theinvention is greater than 50%, and is often greater than 55%.

An additional measure for characterizing the overall aerosol performanceof a dry powder is the fine particle dose (FPD) or fine particlefraction (FPF), which describes the mass percentage of powder having anaerodynamic diameter less than 3.3 microns. Dry powders having an FPFvalue greater than 40%, more preferably greater than 50%, even morepreferably greater than 60% are particularly well suited for pulmonarydelivery. Powders containing at least fifty percent of aerosol particlessized between 0.5 and 3.5 μm are extremely effective when delivered inaerosolized form, in reaching the regions of the lung, including thealveoli.

The spray dried respirable IL-4R powder compositions of the presentinvention are further characterized as having an essentially unchangedmonomer content as compared to that of its pre-spray dried solution orsuspension. In other words, the spray drying process does not induce theformation of dimers or other aggregates, thereby affecting the percentmonomer in the composition. That is to say, the change in monomercontent between spray dried powder and pre-spray dried solution orsuspension is “essentially unchanged”, e.g., the percentage of monomercontent of spray dried powder as compared to that of the pre-spray driedsolution or suspension is preferably no more than about 15%, morepreferably no more than about 10%, more preferably no more than about7%, even more preferably about 5% or less, as exemplified by therepresentative IL-4R powders described in the Examples.

The spray dried respirable IL-4R powder compositions of the presentinvention are “storage stable”, i.e., characterized by minimal insolubleaggregate formation and/or a minimal decrease in monomer content, whenstored for extended periods at extreme temperatures (“temperaturestable”) and humidities (“moisture stable”). For example, the spraydried respirable IL-4R powder compositions of the present inventionexperience minimal aggregate formation and minimal decrease in monomercontent after storage for a period of time (e.g., two weeks or more) ata temperature ranging from about 2° C. to about 50° C., preferably about25° C., and/or a relative humidity ranging from 0% to about 75%,preferably about 33% RH. Specifically, the stored spray dried respirableIL-4R powder compositions of the present invention preferably form lessthan about 15% insoluble aggregates (as compared to the pre-spray driedsolutions or suspensions), more preferably less than about 10% insolubleaggregates, more preferably less than about 7% insoluble aggregates,even more preferably about 5% or less insoluble aggregates.Alternatively, the stored spray dried respirable IL-4R powdercompositions of the present invention preferably experience a decreasein monomer content that is no more than about 20%, preferably no morethan about 10%, more preferably no more than about 7%, even morepreferably about 5% or less.

It is important to note the distinctions between respirable powder-basedformulations and nebulized formulations. Despite the fact that nebulizedformulations may be considered by some to be “inhaleable”, in that theyare breathed through the mouth and into the lungs, they are not“respirable” as defined herein. For example, nebulized formulationstypically cannot reach the tissues of the deep lung and be absorbedthrough the epithelial cells therein into blood circulation. Moreovernebulized formulations are solution-based, i.e., are administered insolution rather than in solid form.

Representative respirable IL-4R powder compositions for pulmonarydelivery are provided in Examples 1-5.

F. Pulmonary Administration of the Respirable IL-4R Powder Compositions

The respirable IL-4R powder compositions, particularly the dry powdercompositions described herein, are preferably delivered using anysuitable dry powder inhaler (DPI), i.e., an inhaler device that utilizesthe patient's inhaled breath as a vehicle to transport the previouslydispersed (by passive or active means) dry powder to the lungs.Preferred are Inhale Therapeutic Systems' dry powder inhalation devicesas described in Patton, J. S., et al., U.S. Pat. No. 5,458,135 (1995);Smith, A., et al., U.S. Pat. No. 5,740,794, (1998); Smith A., et al.,U.S. Pat. No. 5,785,049(1998), and in International Patent applicationPCT 00/18084.

When administered using a device of this type, the respirable IL-4Rpowder composition is contained in a receptacle having a puncturable lidor other access surface, preferably a blister package or cartridge,where the receptacle may contain a single dosage unit or multiple dosageunits. Large numbers of cavities are conveniently filled with metereddoses of dry powder medicament as described in Parks, D. J. et al.,International Patent Publication WO 97/41031 (1997).

Also suitable for delivering the respirable IL-4R powder formulationsdescribed herein are dry powder inhalers of the type described, forexample, in Cocozza, S., U.S. Pat. No. 3,906,950 (1974), and Cocozza,S., U.S. Pat. No. 4,013,075, (1977), wherein a premeasured dose of drypowder for delivery to a subject is contained within a hard gelatincapsule.

Other dry powder dispersion devices for pulmonary administration of drypowders include those described, for example, in Newell, R. E. et al.,European Patent No. EP 129985, (1988); in Hodson, P. D. et al., EuropeanPatent No. EP 472598, (1996); in Cocozza, S., et al., European PatentNo. EP 467172, (1994), and in Lloyd, L. J. et al., U.S. Pat. No.5,522,385, (1996). Also suitable for delivering the IL-4R powdercompositions of the invention are inhalation devices such as theAstra-Draco “TURBUHALER”. This type of device is described in detail inVirtanen, R., U.S. Pat. No. 4,668,218); in Wetterlin, K. et al., U.S.Pat. No. 4,667,668, (1987); and in Wetterlin K., et al., U.S. Pat. No.4,805,811, (1989). Also suitable are devices which employ the use of apiston to provide air for either entraining powdered medicament, liftingmedicament from a carrier screen by passing air through the screen, ormixing air with powder medicament in a mixing chamber with subsequentintroduction of the powder to the patient through the mouthpiece of thedevice, such as described in Mulhauser, P., et al., U.S. Pat. No.5,388,572, (1997).

The inhaleable IL-4R powder compositions may also be delivered using apressurized, metered dose inhaler (MDI) containing solution orsuspension of drug in a pharmaceutically inert liquid propellant, e.g.,a chlorofluorocarbon or fluorocarbon, as described in Laube, et al.,U.S. Pat. No. 5,320,094, (1994), and in Rubsamen, R. M. et al., U.S.Pat. No. 5,672,581 (1994). Prior to use, the respirable IL-4R powdercompositions are generally stored in a receptacle under ambientconditions, and preferably are stored at temperatures at or below about25° C., and relative humidities (RH) ranging from about 30 to 60%. Morepreferred relative humidity conditions, e.g., less than about 30% may beachieved by the incorporation of desiccating agent in the secondarypackaging of the dosage form. The respirable dry powders of theinvention are characterized not only by good aerosol performance, but bygood stability, as well.

When aerosolized for direct delivery to the lung, the IL-4R powdercompositions described herein will exhibit good in-lungbioavailabilities.

G. Utility

The respirable IL-4R powder compositions of the invention, whenadministered pulmonarily, are particularly effective in the treatment ofallergic diseases and disorders, such as asthma, atopy, atopicdermititis, and other conditions associated with high serum levels ofIgE and IgG₁.

The respirable IL-4R powder compositions can also be used for treatingor preventing allergic, viral, parasitic, and bacterial diseases andmildew infectious diseases, particularly when administered incombination with γ-interferon. (See European Patent No. EP 585,681(1994)).

The inventive powder compositions, when inhaled, penetrate into theairways of the lungs, enter the circulatory system and achieve effectivesystemic delivery. Moreover, the doses of IL-4R powder administeredpulmonarily are typically much less than those administered orally dueto the loss associated with digestion and degradation for oral dosageforms.

The respirable IL-4R powder compositions of the present invention findutility as alternates or adjuncts to current asthma therapies.

The respirable IL-4R powder compositions find particular utility in thephysiological regulation of serum levels of IL-4 and immunoglobulinsassociated therewith (e.g., IgE, and IgG₁).

The respirable IL-4R powder compositions find further utility asenhancers of the biological activity of the cytokine IL-4, therebyallowing for the reduction in cytokine dosage required and theminimization of negative side effects associated therewith (See U.S.Pat. No. 6,063,371, incorporated by reference herein).

The following examples illustrate, but in no way are intended to limitthe scope of the present invention.

EXAMPLES

Materials and Methods

The following materials were used in the examples below

Materials

L-Leucine (Aldrich, St. Louis, Mo.)

Hydrochloric Acid (J. T. Baker, Phillipsburg, N.J.)

Sodium Hydroxide 0.1N Volumetric Solution (J. T. Baker, Phillipsburg,N.J.)

Ethanol, 200 proof (USP/NF, Spectrum Chemical Mfg. Corp., New Brunswick,N.J.)

Methanol (HPLC grade, EM Industries, Gibbstown, N.J.)

Recombinant Human IL-4R (rhuIL-4R) (Immunex Corporation, Seattle, Wash.)

Male Sprague Dawley Rats (Simonsen laboratories, Gilroy, Calif.)

Powder Analysis

IL-4R Solutions: The following solutions of IL-4R were prepared.Solution A contained 22.6 mg.mL of serum free IL-4R in 5 mM NaH₂PO₄buffered to a pH of 7.0. Solution B contained 6.1 mg/mL of serum freeIL-4R in distilled water. The solution concentrations are expressed asmass of peptide per unit volume. Values reported herein are from aminoacid analysis data; values from UV testing were slightly higher (25.6and 7.8 mg. mL, respectively).

Particle Size. The particle size distribution of the exemplary IL-4Rpowders was measured by liquid centrifugal sedimentation in a HoribaCAPA-700 Particle Size Analyzer following dispersion of the powders inSediSperse A-11 (Micrometrics, Norcross, Ga.).

Moisture Content. The moisture content of the powders was measured bythe Karl Fischer Titrimetric technique using a Mitsubishi CA-06 MoistureMeter or by thermogravimetric analysis.

MMADs. The aerosol particle size distribution (MMAD) was determinedusing a cascade impactor (Graseby Andersen, Smyrna, Ga.) at a flow rateof 28 L/min, ignoring powder loss of the inlet manifold.

Emitted Dose. Emitted doses were determined as described in the“Definitions” section using an Inhale dry powder inhaler as described inU.S. Pat. No. 5,740,794 and a Gelman glass filter, 47 mm diameter.

Scanning Electron Microscopy (SEM). Particle morphology was determinedusing an XL 30 ESEM manufactured by Philips Electron Optics (Eindhoven,The Netherlands).

Thermal Analyses. Thermal analysis experiments were conducted using amodulated Differntial Scanning Calorimeter (mDSC-Model 2920) DielectricAnalyzer (DEA 2970) and a Thermal Gravimetric Analyzer (TGA Model 2950manufactured by TA Instruments (New Castle, Del.). Hot stage microscopywas conducted using a Nikon Optiphot-2-pol optical microscope (NikonInc., Torrance, Calif.), a Hamatsu camera and C2400 controller (HamatsuPhotonics, herrsching, German7), a Mettler-Toledo FP90 central processor(Mettler-Toledo, Columbus, Ohio) and FP8902H hot stage attachment(Mettler, Toledo, Ohio).

Chemical Characterization: SE-HPLC experiments were run on a Waters HPLCAlliance model 2690 system (Alliance HPLC Systems, Millford, Mass.)running Millenium V software (Waters). Chromatography columns wereobtained from Phenomenex (Torrance, Calif.). UV experiments wereperformed on a Hitachi U-3000, dual beam spectrophotometer (HitachiInstruments Inc., San Jose, Calif.). SDS-PAGW experiments were performedon Novex Xcell electrophoreses unit (Novex, San Diego, Calif.).

Example 1 Preparation of IL-4R Dry Powders

Storage stable spray-dried powders of the interleukin receptor protein,IL-4R, having superior aerosol properties and further characterized bysuperior chemical and physical stabilities were prepared. Powders wereprepared in both the presence and absence of excipients; excipientsemployed were from a variety of representative chemical classes (e.g.,organic acid salts, amino acids, metal cations). The IL-4R powders arestable upon long-term storage and are resistance to extreme conditionsof temperature and humidity.

Representative IL-4R powders were prepared according to the followingprotocols.

Example 1 (A) Neat Formulation of IL-4R

Dry powder compositions of IL-4R were formulated in deionized waterwithout added excipients for spray-drying. 600-700 mg batches of theneat formulation of IL-4R were prepared by spray drying an appropriatevolume of Solution A. The final concentration of phosphate buffer in thepre-spray dried solution was 1.9 mM.

Example 1 (B) Zinc Chloride Containing Formulation of IL-4R

Dry powder compositions of IL-4R were formulated in deionized water withzinc chloride for spray-drying. 600-700 mg batches of a 5.4:1 ZnCl₂:IL-4R formulations were prepared by dispensing 19.53 mL of IL-4RSolution A and 0.456 mL of a 19.37 mg/mL solution of ZnCl₂ into a 50 mLvolumetric flask and adjusting the final volume to 50 mL by addition ofdeionized water. The final concentration of phosphate buffer was 1.9 mM.

Example 1(C)

Citrate Containing Formulation of IL-4R

Dry powder compositions of IL-4R were formulated in deionized watercontaining a citrate salt for spray-drying. 600-700 mg batches ofcitrate: IL-4R formulations were prepared by combining approximately 12mL of Solution A and 200 mg of citrate in solution at pH 7.5 andadjusting to a final volume of 50 mL by addition of deionized water. Thefinal concentration of phosphate buffer was 1.2 mM.

Example 1(D) Leucine Containing Formulation of IL-4R

Dry powder compositions of IL-4R were formulated in deionized watercontaining leucine for spray-drying. 600-700 mg batches of the leucine:IL-4R formulations were prepared by combining approximately 12 mL ofSolution A and 200 mg of leucine and adjusting to a final volume of 50mL by addition of deionized water. The final concentration of phosphatebuffer was 1.2 mM and the pH was 7.5.

Relative Amounts of Components (wt/wt) in Formulations 1(A)-1(D) aresummarized in Table 1 below. TABLE 1 Formulations of IL-4R CitrateLeucine Formulation IL-4R % Phosphate % ZnCl₂ % % % Neat IL-4R 98.0 2.00.0 0.0 0.0 5.4:1 Zn:IL4R 96.9 1.9 1.2 0.0 0.0 Citrate:IL-4R 66.3 1.30.0 32.4 0.0 Leucine:IL-4R 66.3 1.3 0.0 0.0 32.4

Additional powder formulations contemplated include IL-4R formulations,both neat and excipient containing, prepared using a citrate buffered ora water-based (no buffer) IL-4R solution. Preferred IL-4R powders inaccordance with the invention comprise, in addition to IL-4R, one ormore of the following excipients: trileucine, raffinose, mannitol,sucrose, F-68, divalent metal cations such as magnesium, calcium, andthe like, glucophosphate, zinc salts, trehalose, glycine and histidine.Specific formulations may comprise from 10-40 weight % trileucine, or 1%by weight F-68, or 10% by weight citrate, or 3:1 to 10:1 by weightcationic divalent metal cation: IL-4R, or 10-30% by weight sucrose, or5-50% by weight trehalose, or any combination of the above. Additionalillustrative IL-4R formulations include those containing both citrateand leucine (e.g., a formulation with a citrate: leucine: IL-4R ratio of15:15:70) or raffinose (e.g., formulations comprising 5%-50% raffinose).

The above IL-4R formulations above were spray dried using a laboratoryscale Buchi mini spray-dryer (Buchi Labortechnik, Ag., Meierseggstrasse,Switzerland) fitted with a modified cyclone, an atomizer nozzle and apowder collection vessel. The atomizer of the Buchi spray dryer wasoperated with clean dry air. The liquid flow rate into the Buchi was 5mL/min. The inlet temperature was adjusted to achieve the targetparticle size and morphology (80° C. to 150° C.). The outlet temperatureranged from about 30° C. to 100° C. Yields were greater than 75% rangingfrom 78-91% for the IL-4R formulation lots 1(A)-1(D). The IL-4R powders(3±0.15 mg) were transferred into a glovebox with a relative humidityless than 5% and placed into unit dosage forms (blister packs, BP's)suitable for use in a dry powder inhaler device as described in U.S.Pat. No. 5,740,794. Evaluation and characterization of the resultingsolids is described below.

Example 2 Stability of IL-4R Powder Formulations

The purpose of the studies of Examples 2-5 was to evaluate aerosolperformance, physical, and chemical stability of the representativeIL-4R dry powder formulations described in Example 1. Aerosol, thermal,physical, and chemical tests were performed on the powders as initiallyprepared. Thermal and physical and chemical analyses were also performedafter 2 weeks storage at four different temperatures (2-8° C., 25° C.,40° C. and 50° C.) and 3 relative humidities at 25° C. (0, 33 and 75%).The stability protocol is set forth below:

Powders were filled into foil/PVC blister packs and assayed for emitteddose, particle size distributions and thermal analyses at initial timepoints only. Chemical characterization and SEM analyses were performedon bulk aerosol drug powders (i.e., not contained in blister packs) atinitial and 2 week timepoints. All powders were handled inhumidity-controlled glove boxes with a relative humidity of less than5%.

Bulk powder was weighed into borosilicate glass vials in a glove box.For 0% relative humidity (RH) stability samples, vials were capped,placed into a foil overwrap pouch containing desiccant and heat-sealedbefore storing in temperature chambers. For humidity controlledstability samples, vials were left open and stored in desiccators at 25°C. Samples were pulled and analyzed by UV, SDS-PAGE, SE-HPLC and SEMafter 2 weeks. TABLE 2 Summary of Stability Protocol for IL-4R SprayDried Bulk Powders and Stock Solutions Testing Conditions 2 Weeks³ 2-8°C./ 25° C./ 25° C./ 25° C./ 40° C./ 50° C./ Test Initial 0%/RH 0%/RH33%/RH 75%/RH 0%/RH 0%/RH DDE¹ X MMAD¹ X DSC¹ X TGA¹ X UV² X X X X X X XSE-HPLC² X X X X X X X SDS-PAGE² X X X X X X X SEM X¹ X² X² X² X² X² X²¹test performed using blister packs²test performed using bulk powder³bulk aerosol powder stored in borosilicate glass vials capped andparafilmed in a sealed foil overwrap4 bulk aerosol powder stored in borosilicate glass vials with caps off

TABLE 3 Aqueous Dilutions from Stock Testing Conditions 2 Weeks⁶ TestInitial⁵ 25° C. 50° C. UV X X X SE-HPLC X X X ASA-PFW X X X⁵solution diluted with water from IL-4R Solution A⁶1 mL of a 1 mg/mL IL-4R solution stored in borosilicate glass vialscapped and parafilmed in a sealed foil overwrap

Example 3 Aerosol Performance of IL-4R Powder Formulations

Aerosol tests were performed using a dry powder inhaler as described inU.S. Pat. No. 5,740,794, assigned to Inhale Therapeutic Systems Inc. Allof the filled blister packs were stored in a dry box prior to use foraerosol testing.

Example 3(A) Emitted Dose

The emitted dose was measured by collecting the aerosol on a glass fiberfilter placed in a holder over the mouthpiece of the chamber of thedevice. To measure the emitted dose percent (ED %), a blister pack wasdispersed as an aerosol using a dry powder inhaler as described above.The powder sample was collected on a pre-weighed glass fiber filter(Gelman, 47 mm diameter). The aerosol cloud was collected onto thefilter from the chamber by drawing at an airflow rate of 30±0.5 L/minfor 2.5-3.5 seconds. An automatic timer controlled the duration of thedraw. The sampling pattern simulates a patient's slow deep inspiration.

The ED % was calculated by dividing the mass of the powder collected onthe filter by the mass of powder in the blister pack (actual mass).Results are reported in Table 4. Each result reported was the averageand standard deviation of 10 measurements.

Example 3(B) Mass Median Aerodynamic Diameter (MMAD) and GeometricStandard Deviation (GSD)

Mass Median aerodynamic diameter and particle size distribution of theaerosol were obtained using an 8-stage (9.0, 5.8, 4.7, 3.3, 2.1, 1.1,0.7, and 0.4 μm cut sizes) Andersen Cascade Impactor. Each Andersenmeasurement was obtained by dispersing 10 blister packs of 3 mg fillweight in a dry powder inhaler while pulling a vacuum at 28.3±0.5 L/minfor 2.5 seconds. An automatic timer controlled the duration of the draw.From this data a mass median aerodynamic diameter was calculated.Results are set forth in Table 4.

Geometric standard deviations (GSD's) were calculated graphically fromthe Andersen MMAD data. The plate cut-off diameter was plotted as afunction of the cumulative percent undersize on a probability scale. TheGSD was taken as the diameter at 85% divided by the diameter at 50%.Values obtained are listed in Table 4.

Example 3(C) Fine Particle Fraction (FPF)

The FPF_(%<3.3 μm) was obtained by using the Andersen cascade impactorstages F and 3 in short stakc set up. Each FPF measurement was obtainedby dispersing 2 blister packs of 3 mg fill weight in a dry powderinhaler while pulling a vacuum at 28.3 L/min for 2.5 seconds. Resultsare set forth in Table 4. TABLE 4 Initial Aerosol Test Results for IL-4RFormulations (3 mg fill weight) Wt % Emitted FPF IL- MMAD Dose (% <3.3GSD Formulation Lot # 4R (μm) (%) μm) (μm) Neat IL-4R NM1392- 98.0 3.959.6 0.43(21)* 1.6 04 (0.12)** 7:1 Zn:IL-4R NM1392- 96.9 4.0 68.60.34(0)* 1.6 05 (0.040** Citrate:IL- NM1392- 66.3 3.7 63.4 0.35(2)* 1.74R 06 (0.09)** Leucine:IL- NM1392- 66.3 2.9 75.9 0.56(6) 2.1 4R 07(0.08)***RSD for n = 3**Values are the mean and RSD, in parentheses, of 10 measurements.

The aerosol performance of the IL-4R powder formulations was quite good,all having ED values of essentially 60% or greater and MMAD values of 4μm or less, with at least 34% or particle having MMADs of less than 3.3μm.

The GSD values were all less than 2 μm, except for the leucineformulation. This was believed to be an artifact due to the observedbi-modal particle size distribution generated from the Andersen CI.

Example 4 Solid State Characterization of IL-4R Powder FormulationsExample 4(A) Scanning Electron Microscopy

Scanning electron microscopy was utilized to obtain initialmorphological information on the spray-dried powders and to assesschanges in morphology upon storage under varying conditions oftemperature and humidity.

Images were taken with a Philips XL30 ESEM operated in high vacuum modeusing a Everhart-Thomley detector to capture secondary electrons for theimage composition. Accelerating voltages were 3 to 10 kV using a LaB₆source. Working distances ranged from 30 to 10 μm.

All powders with the exception of the leucine:IL-4R powder, Formulation1(D), exhibited no appreciable change in morphology after 2 weeksstorage at the temperature and RH condition described in the stabilityprotocol of Example 2 (Table 2). Some of the leucine:IL-4R powdersexhibited morphological changes at RH values at 33 to 75% RH as well asat temperatures of 40 to 50° C., characterized by ribbon-like growthswhich may be due to crystallization of amorphous leucine.

When examined visually by SEM, the particles may exhibit a wrinkled,raisin-like morphology. Rugose particles (i.e., deep wrinkled particlesthat are substantially more rough than smooth) are most preferred.

The effects of temperature and relative humidity for representativeIL-4R formulations was determined. Of the illustrative IL-4R powdersprepared, the leucine spray dried powder appeared to be the leastmorphologically stable, based upon temperature and RH-driven changes inmorphology. No significant morphology changes were noted in any of theother powders when exposed to identical storage conditions.

Example 4(B) Thermal Analysis

Differential Scanning Calormietry (DSC): DSC profiles were generated byheating a sample in hermetically sealed pan in a TA Instruments DSC.Sample weights were on the order of 3.5-4.5 mg. The DSC heating rate was10° C./min with helium as the purge gas. The temperature was initiallyramped to 70° C., cooled at 10° C./min to −30° C., and reheating at 10°C./min to 220° C. in order to remove thermal history instead of usingmodulation mode. All of the powders exhibited a large endotherm atapproximately 198° C. The zinc containing IL-4R formulation, Formulation1(B), exhibited an additional endotherm at about 180° C. The citratecontaining IL-4R formulation, Formulation 1(C), exhibited an additionalendotherm at about 172° C. The leucine containing IL-4R formulation,Formulation 1(D), exhibited an additional endotherm at about 186° C. Noglass transition (Tg) was noted for the powders using this technique.

Thus, the spray dried powders of the invention exhibit glass transitiontemperatures that are much higher than room temperature, a preferredcharacteristic of dry powder formulations, particularly for long-termstorage. Thus, in another aspect, the representative IL-4R powders ofthe invention are characterized by Tgs that are higher than 100° C. Dueto the high Tgs of the powders of the invention, these IL-4R powders canbe stably stored at temperatures in excess of ambient or 25° C., and canbe stably stored at 30° C., 35° C., 40° C., 45° C., 50° C., 55° C., 60°C., 65° C. or greater (up to about 100° C. or even more) for extendedperiods of time (e.g., one week, two weeks, one month, two months, threeto six months, nine months, up to a year or longer), whilst maintainingtheir advantageous aerosol characteristics (exhibiting essentiallyminimal drop in emitted dose, of no more than about 15%, preferably nomore than about 10%, and even more preferably no more than about 5%, andessentially no change in MMAD, as characterized by an increase in MMADof no more than about 1 micron, and preferably no more than about 0.75microns, and even more preferably no more than about 0.5 microns, uponstorage).

Dielectric Relazation Spectrometry (DRS): Sine the glass transitiontemperature (Tg) of the IL-4R spray dried formulations could not bedetermined by DSC, DRS was performed. Two DRS experiments were conductedon the zinc containing IL-4R formulation, Formulation 1(B), to betteridentify the glass transition temperature of a representativeformulation. The first experiment conducted was a standard DRS analysis(TA Instruments Dieletctic Analyzer (DEA 2970)), run at 2° C./min from30° C. to 150° C. and cooled to 30° C. again, scanning throughfrequencies of 1, 10, 100, 10³, and 10⁴ and 10⁵ Hz. The secondexperiment conducted was a softening experiment much like a thermalmechanical analyzer (TMA) run at 2° C./min from 30° C. to 250° C. andscanning through frequencies of 1, 10, 100, 10³, and 10⁴ and 10⁵ Hz.Both experiments were run on the Zn:IL-4R powder as is (Formulation1(B)) and after drying overnight at 100° C. (Formulation 1(B)-(D).

From these studies, it was concluded that there is no glass transitionbelow the decomposition temperature for the dried sample and no glasstransition below 150° C. for the undried sample. This indicates that thechanges in the baseline below 100° C. observed by DSC were not due to aglass transition event. Thus, the Tg of this formulation is greater thanthe decomposition temperature of the protein.

Thermo mechanical Analysis (TMA): The TMA experiments were performed bymonitoring sample thickness during a DRS experiment. The same electrodeconfiguration was used as in the first experiment, except the gasket wasremoved. The ram force was set at 20N and the thickness of the sampleand the temperature were recorded manually every couple of minutes from30° C. to 250° C. The onset of softening is at 224° C. for bothFormulation 1 (B) and Formulation 1 (B)-D. The softening seen in the TMAexperiments is due to degradation and a possibility of a glasstransition happening simultaneously. Since there is no other softeninghappening at lower temperatures, the 1 Hz peaks from the standard DRStests are due to another mechanism such as the onset of side chainmotions or ion conduction and not due to a glass transition (Seyler, R.J., 1994, “Assignment of the Glass Transition”, ASTM, 108-113). If theglass transition happens simultaneously with the decomposition, then inthe sample with the lower 1 Hz loss factor peak may have the glasstransition shifted to a lower temperature as well. Since the standardDEA test was only run to 150° C., it is clear that there is no glasstransition below 150° C. Evaluation of the permitivity versustemperature plots confirmed the standard s-shaped profiles expected forthis type of analysis.

Therman Gravimetric Analysis (TGA): The residual solvent content in thepowder after spray drying was determined by TGA using a TA InstrumentsTGA. Approximately 3 mg of powder was packed into a hermetically sealedaluminum pan in a glovebox at a relative humidity less than 3%. The TGAwas zeroed without the pan and the weight of the powder was recorded inthe comment section. Just prior to analysis the pan was punctured with apin and loaded into the equipment. The scan rate was 10° C./min from25-175° C. The results are shown in Table 5. TABLE 5 Solvent Content byTGA of IL-4R Spray Dried Powders Formulation Lot # Weight % Solvent NeatIL-4R NM1392-04 2.9 7:1 Zn:IL-4R NM1392-05 3.2 Citrate:IL-4R NM1392-063.9 Leucine:IL-4R NM1392-07 2.4

Hot Stage Microscopy (HSM): Hot stage microscopy was conducted from roomtemperature to 220° C. using a Nikon Optiphot-2-pol optical microscope,a Hamatsu camera and C2400 controller, a Mettler Toledo FP90 centralprocessor and FP8902H hot stage attachment. Little to no change in thevisual appearance of the powder was observed with the dry preparations.The neat (NM1392-04) and the zinc (NM1392-05) formulations demonstratedsome particles “popping” or jumping of particles at approximately 80° C.For all formulations evaluated in high temperature immersion oil,channels formed at approximately 90° C., and at 110° C. outgassing wasobserved. It is assumed that this outgassing is due to water loss fromthe powder. The elongated time for this outgassing is consistent withthe downward sloping profiles observed by DSC.

Example 5 Chemical Characterization of IL-4R Powder Formulations

Several techniques can be used to analyze the samples of Example 1 todetermine the extent of aggregation and degradation. Insolubleaggregates were determined by visible detection and UVspectrophotometry. Soluble aggregates were analyzed quantitatively bysize exclusion chromatography and qualitatively by SDS-PAGE.

Example 5(A) Size Exclusion High pressure Liquid Chromatography(SE-HPLC)

Soluble aggregates were measured quantitatively by SE-HPLC. Samples werestored at 5° C. until injection. Chomatograms were extracted andprocessed at 220 nm.

The percentage monomer content of the formulated solutions before spraydrying was compared to the corresponding reconstituted aerosol drugpowders. There were no significant changes in the percentage monomercontent between the formulated solutions and the reconstituted aerosoldrug powders. Results are set forth in Table 6 below.

Based on results obtained from the powder stability temperature data attwo weeks, as the storage temperature increased, the amount of monomercontent compared to the initial time data decreased. The largest changein percentage monomer from initial was at 50° C. with a range of 2.1%,in the neat formulation, to 1.9% in both the zinc and citrateformulations. In the 2 week powder stability humidity study, the citrateformulations exhibited the largest drop of just 1.8% in monomer frominitial at the extreme RH of 75%. This was probably due to citratecrystallization. Thus, the IL-4R compositions of the invention exhibitessentially no thermal degradation upon spray-drying (as evidenced bymonomer content of the illustrative compositions), and exhibit a minimaldecrease in monomer upon storage, under a variety of illustrativetemperature and humidity conditions. Unlike other proteins, which uponspray drying are often prone to significant aggregation (Maa, Y. F., etal., J. of Pharmaceutical Sciences, Vol 87 (2), p. 152-159 (1997)),IL-4R has been found to be surprisingly resistant and impervious to suchconditions, and forms spray-dried powders in which the protein exhibitsinsignificant degradation even in the absence of commonly-employedstabilizing/protecting excipients.

Two 1 mg/mL liquid samples stored at 25 and 50° C. for 2 weeks wereevaluated as controls. The liquid sample stored at 25° C. had a 0.7%dimer content expressed as a percentage of monomer, but had over 17% oflow molecular weight species. At 50° C., the liquid had 2.3% dimercontent expressed as a percentage of monomer and 2.1% of low molecularweight species. Samples were prepared and retested and the originalresults were confirmed. The percentage drop in monomer content of theIL-4R liquid formulation at 50° C. for 2 weeks is approximately 40% frominitial (See Table 6 and FIGS. 1, 2, and 3), while powdered formulationsremained essentially unchanged. Thus, solution formulations of IL-4R aresignificantly more unstable (i.e., prone to degradation) than thecorresponding powder formulations stored under essentially the sameconditions for a given period of time. Interestingly, the extremeconditions of temperature and shear experienced by the IL-4R molecule insolution during spray-drying did not cause a significant drop in monomercontent or promote extensive chemical degradation of the molecule suchas that observed for the liquid samples placed on storage. The abovedata points to the striking advantage of powder formulations of IL-4Rover corresponding liquid formulations upon storage, based upon bothchemical and physical stability data.

Example 5(B) Ultraviolet Spectroscopy (UV)

UV spectrophotometric analyses were used to evaluate turbidity (i.e.,aggregation/precipitation) in reconstituted samples. Measurements wereperformed on a Hitachi U-3000, dual beam spectrophotometer. Instrumentparameters were set at a scan rate of 300 nm/min; 1.0 nm slit width; anda scan ranged from 450 nm to 200 nm. Samples were visually inspected forparticulate matter. Insoluble aggregates were determined quantitativelyby measuring the turbidity of the solution with UV. Linear regression tocorrect for scatter was performed from absorbance values at 350, 375 and400 nm. Absorbance at λ_(max) corrected for light scattering wasextrapolated from the equation for the regression line. The percentinsoluble aggregate is the percentage of absorbance corrected for lightscattering, divided by absorbance uncorrected at λmax as shown in Eq. 1below. $\begin{matrix}{{\%\quad{percent}\quad{insoluble}\quad{aggregates}} = \frac{{Abs}\quad{\lambda_{\max}\left( {{light}\quad{scatter}\quad{corrected}} \right)}}{{Abs}\quad{\lambda_{\max}\left( {{light}\quad{scatter}\quad{uncorrected}} \right)}}} & \left( {{Eq}.\quad 1} \right)\end{matrix}$

Samples were either reconstituted or diluted to a concentration of 0.1mg of IL-4R peptide/mL with water prior to analysis.

Except for one sample, all solution samples, before and after spraydrying, had no visible signs of particulate matter or had less than 5%calculated insoluble aggregates. The spray dried neat formulation,Formulation 1(A), was visibly clear under initial conditions but had 7%insoluble aggregates, when calculated by Eq 1. Since the 2 weekstability time point for this sample contained only 3% insolubleaggregates, it was concluded that the initial value was in error. Allsamples after exposure for 2 weeks to specified temperature and humidityconditions exhibited no visible signs of particulates or detectableinsoluble aggregates. Less than 3.5% insoluble aggregates werecalculated using Eq. 1 for all batches. Table 6 includes data collectedonly by SE-HPLC and does not contain insoluble aggregate information.TABLE 6 Aggregation Summary for IL-4R Formulations (SE-HPLC) MonomerContent (%) Neat Zn:IL-4R Citrate Leucine Initial 2 weeks Initial 2weeks Initial 2 weeks Initial 2 weeks Pre-SD Solution 96.4 96.0 95.096.1 2-8° C. 96.5 96.0 96.2 95.9 95.1 94.7 96.0 95.9 25° C. 96.5 96.096.2 95.6 95.1 94.6 96.0 95.6 40° C. 96.5 95.4 96.2 95.0 95.1 94.3 96.095.3 50° C. 96.5 94.4 96.2 94.3 95.1 93.2 96.0 94.6 25° C./0% RH 96.596.0 96.2 95.6 95.1 94.6 96.0 95.6 25° C./33% RH 96.5 95.7 96.2 95.495.1 94.5 96.0 95.3 25° C./75% RH 96.5 95.4 96.2 95.3 95.1 93.5 96.094.9

Example 5(C) Sodium Dodecyl Sulfate-PolyacrEylamide Gel Electrophoresis(SDS-PAGE)

Soluble aggregates and degradation were measured qualitatively by SDSPAGE using a Novex Silver Xpresss staining kit. Novex pre-cast 4-20%tris-glycine gels were run on a Novex Xcell II electophoresis mini-cell.Samples were either reconstituted or diluted to a concentration of 0.1mg of IL-4R peptide/mL with water. Solutions were prepared underreducing and non-reducing conditions and applied at a load of 1-5 μg ofprotein per lane. The 5 μg protein loads were run to try and enhancedetection of bands not observable in the 1 μg protein load. Reducedsamples were treated with 2-mercaptoethanol and heated at 100° C. for 3minutes. Gels were run at 125V, 25 mA/gel until the gel front reachedthe bottom (approx 1.5 hrs). In addition to the pre-spray dry solution,initial powders, and stability samples, a solution of 1 mg IL-4Rpeptide/mL was analyzed as a control Reducing and non-reducing gels wererun for the liquid formulation at initials, 2 weeks, 25° C. and 2 weeks,40° C.

There were no changes in the gel profiles between the formulatedsolutions before spray drying and the reconstituted aerosol drugpowders. The monomer bands of all samples and controls of IL-4R on thegels ran at higher molecular weight (approx. 50 kDa) than reportedvalues and appear broad and diffuse. This is most likely attributed tothe protein being a glycoslyated and affecting the migration of IL-4Rthrough the gel. There was another distinct band running atapproximately 97 kDa, this was attributed to the dimer which ispresumably the dimer form of the protein. Several lower molecular weightbanks were visible in the 5 μg load gel that have not been identified.

As with the initials, there were no visible changes in the stability gelprofiles of the 2 weeks bulk aerosol powder in either the temperature ofthe humidity studies compared to the control solution. The neat IL-4Rsample incubated at 25° C., 75% RH for two 2 weeks was not detected inthe original gel, probably due to dilution error. Upon repeat analysis,the sample was equivalent to the other stability samples. Gels of theIL-4R solution samples showed a great degree of degradation andaggregation compare to the spray dried powders.

In sum, based on the results obtained from the stability study, IL-4Rwas observed to be chemically stable in all four lots of bulk powderformulations (Formulations 1(A)-1(D)) for up to two weeks at 2-8° C.,25° C., 40° C. and 50° C., in addition to 25° C. at 0%, 33% and 75% RHfor powders stored naked. No insoluble aggregation was observed by UVfor all the batches. Monomer content dropped by less than 2% for allformulations at these conditions, with the citrate formulationexhibiting the greatest reduction in monomer content upon storage.

The disclosure of each publication, patent or patent applicationmentioned in this specification is incorporated by reference herein tothe same extent as if each individual publication, patent or patentapplication were specifically and individually indicated to beincorporated by reference.

Although the foregoing invention has been described in some detail byway of illustration and example, for purposes of clarity ofunderstanding, it will be apparent to those skilled in the art thatcertain changes and modifications may be practiced within the scope ofthe appended claims.

1. A method for preparing a dry IL-4R powder composition, said methodcomprising: (a) preparing a mixture or a solution of IL-4R in a solvent,and (b) spray-drying the mixture or solution to obtain a spray-driedpowder comprising IL-4R.
 2. The method of claim 1, wherein the mixtureor solution of IL-4R further comprises an excipient.
 3. The method ofclaim 2, wherein the excipient is selected from the group consisting ofcarbohydrates, amino acids, oligopeptides, peptides, and proteins. 4.The method of claim 3, wherein the excipient is a carbohydrate.
 5. Themethod of claim 4, wherein the carbohydrate is a sugar or sugar alcohol.6. The method of claim 3, wherein the excipient is an amino acid.
 7. Themethod of claim 6, wherein the amino acid is a hydrophobic amino acid.8. The method of claim 2, wherein the excipient is selected from thegroup consisting of citrate salts, leucine, raffinose, zinc salts, andcombinations thereof.
 9. The method of claim 2, wherein the excipient isa buffer.
 10. The method of claim 2, wherein the excipient is a divalentmetal cation.
 11. The method of claim 1, wherein the spray-dried powdercomprises particles having a mass median aerodynamic diameter (MMAD) ofless than about 10 microns.
 12. The method of claim 1, wherein thespray-dried powder comprises particles having a mass median aerodynamicdiameter (MMAD) of less than about 5 microns.
 13. The method of claim 1,wherein the spray-dried powder comprises particles having a mass medianaerodynamic diameter (MMAD) of less than about 3.5 microns.
 14. Themethod of claim 1, wherein the spray-dried powder comprises particleshaving a mass median diameter (MMAD) of between about 0.1 to 3 microns.15. The method of claim 1, wherein the spray-dried powder has a residualmoisture content of less than about 10% by weight.
 16. The method ofclaim 1, wherein the spray-dried powder has a residual moisture contentof less than about 5% by weight.
 17. The method of claim 1, wherein thespray-dried powder has a bulk density ranging from about 0.1-10 g/cc.18. The method of claim 1, wherein the mixture or solution of IL-4Rcontains IL-4R dissolved in a concentration from 0.01% (weight/volume)to 20% (weight/volume).
 19. The method of claim 1, wherein the solventcomprises a water-miscible solvent.
 20. The method of claim 1, whereinthe water-miscible solvent is selected from the group consisting ofacetane and alcohols.